How EnerTherm Engineering’s Boiler Burner Upgrades Save Up to 40% on Energy Costs

How EnerTherm Engineering's Boiler Burner Upgrades Save Up to 40% on Energy Costs 2

In today’s industrial landscape, energy efficiency isn’t just a buzzword—it’s a crucial element for operational excellence and sustainability. At EnerTherm Engineering, we specialize in enhancing energy performance through innovative solutions, ensuring that factories achieve significant energy savings and reduce operational costs. In this blog post, we explore our proven methodologies for upgrading boiler burners and related systems, demonstrating how these upgrades can save up to 40% of energy in your factory.

Sub-Metering for Enhanced Monitoring

Effective energy management begins with accurate measurement. Our i-Log data logging and reporting system offers comprehensive sub-metering for gas and electricity. This system provides real-time and periodic summaries via an intuitive dashboard, empowering you to make informed decisions regarding capital and operational expenditures. This visibility is crucial for identifying inefficiencies and optimizing energy use across your factory.

Combustion Management and O2 Trimming

Controlling the air-to-gas ratio is pivotal for maintaining optimal combustion efficiency. Our advanced combustion management system automatically adjusts the air requirements, preventing the adverse effects of under or over-aired conditions, such as increased emissions and higher running costs. This adjustment alone can boost efficiency by 3-6%.

Pre-Heating Combustion Air

Cold combustion air significantly hampers process efficiency. By integrating a heat exchanger into the waste gas stream, we can pre-heat the combustion air, thereby enhancing efficiency by 3-10%, depending on the temperature of the pre-heated air. This simple yet effective upgrade maximizes heat recovery and minimizes energy waste.

Insulation and Refractory Replacement

Over time, insulation degrades due to factors like water ingress, leading to increased heat losses and energy consumption. A heat survey can identify areas requiring repair or improvement. By replacing or upgrading insulation, factories can achieve efficiency gains of 3-6%, contributing to lower energy bills and reduced emissions.

Steam Boiler Enhancements

Steam boilers are integral to many industrial processes. We offer cost-effective tube inserts that enhance heat transfer efficiency, resulting in 4-7% gains. Additionally, applying thermal coating to the combustion walls reduces heat loss, further improving efficiency by 2-5%.

Voltage Optimization

Reducing the incoming voltage supply to an optimal level can significantly decrease electricity usage and extend the lifespan of your equipment. This approach not only enhances energy efficiency by 5-8% but also ensures smoother and more reliable operations.

Quantifying Efficiency Gains

Let’s break down how to calculate the efficiency gains from upgrading your boiler burner system in a simple, step-by-step way.

Step-by-Step Calculation

Step 1: Understand the Basics

  • Energy Used for Heating: This is the amount of energy (in kilowatts, kW) required to heat your product (like oil) to the desired temperature.
  • Total Energy Input: This is the total amount of energy (in kW) your system uses, as measured by the gas or electricity meter.

Step 2: Calculate Your Current Efficiency

  1. Energy Used for Heating: Suppose your system needs 5000 kW to heat the oil.
  2. Total Energy Input: Suppose the energy input from your gas meter is 7200 kW.

To find the current efficiency, use this formula:

Efficiency = (Energy Used for Heating / Total Energy Input) × 100

Plugging in the numbers:

Efficiency = (5000 / 7200) × 100 ≈ 69.4%

Step 3: Determine the Cost Savings from Efficiency Improvement

Let’s see how much money you can save with a 1% efficiency improvement.

  1. Annual Energy Cost: Suppose you spend £850,000 per year on gas.
  2. Current Efficiency: 69.4% (from Step 2).

The formula to calculate the value of a 1% efficiency improvement is:

Value of 1% Efficiency Improvement = Annual Energy Cost \ Current Efficiency

Plugging in the numbers:

Value of 1% Efficiency Improvement = 850,000 / 69.4 ≈ £12,247

Step 4: Calculate Total Savings from the Expected Efficiency Improvement

Suppose you aim to improve your efficiency by 6%. To find the total savings:

Total Savings = Value of 1% Efficiency Improvement x Efficiency Improvement Percentage

Using the numbers from the previous steps:

Total Savings = 12,247 × 6 ≈ £73,482

So, if your efficiency improves by 6%, you could save about £73,482 annually.

Industry Insights and Best Practices

Recent industry reports highlight the growing importance of energy efficiency in manufacturing. According to the International Energy Agency (IEA), improving energy efficiency could lead to a reduction of global energy demand by 12% by 2040, significantly cutting greenhouse gas emissions and operational costs. Furthermore, the adoption of smart manufacturing technologies can enhance energy efficiency by providing real-time data and analytics to optimize production processes.


EnerTherm Engineering‘s comprehensive approach to boiler burner upgrades delivers measurable energy savings and operational improvements. By focusing on sub-metering, combustion management, pre-heating, insulation, and voltage optimization, we help factories achieve substantial efficiency gains. Contact us today to learn how we can transform your energy performance and drive your factory towards a more sustainable and cost-effective future.

Picture of Francois Pierrel
Francois Pierrel
Hi, my name is François and I am passionate about solving process engineering problems. Over the years, I have developed a number of process equipment and control systems which have had a significant impact on reducing energy usage, waste and impact on the environment. My business ethos is to always get to the root cause of problems and data analysis and modelling are always at the forefront of any project we undertake.
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